Apparatus for increasing the density of thermoplastic foam

ABSTRACT

A method and apparatus for densifying thermoplastic foam wherein the foam cells are crushed by mulling within a narrow chamber formed by plates or members mounted for relative rotation with respect to each other. The densified foam emerges as a high density curdlike extrudate at the periphery of the members.

United States Patent Inventors Mario Serrano; [56] RelerencesCited William D. Wolf, Simsbury, Conn. UNITED STATES PATENTS Q A- 333 274,209 3/1883 McCully No 1,961,862 6/1934 Park 2,129,789 9/1938 Seaborne. E 1 3,009,685 11/1961 Rettig 2 8 3 3,256,568 6/1966 Stenger fmmg 3,346,917 10/1967 Lennox FOREIGN PATENTS 501,028 2/1951 Belgium 1,007,862 1962 Japan APPARATUS FOR INCREASING TI-IE DENSITY OF Primary Examiner-J. Spencer Overholser Assistant Examiner-Michael 0. Sutton Attorneys-Michael J. Murphy, James C. Logomasini and- THERMOPLASTIC FOAM 4 Drawing I Herbert B. Roberts US. Cl 18/125M, I

18/30AF, 146/ 165 ABSTRACT: A method and apparatus for densifying ther- Int. Cl B29t 3/02 moplastic foam wherein the foam cells are crushed by mulling Field of Search 18/30 within a narrow chamber formed by plates or members (AF,SN), l2 (SF,SH,ST,SV), 30 (Y), 1 (A); 264/321, 163,68, 117, 80, 140, 1l8;24l/246,

247, 167; 146/ 165, 71.5 the periphery of the members.

0 M Z f IZLT /11 mounted for relative rotation with respect to each other. The densified foam emerges as a high density curdlike extrudate at PATENTEU m 4|s7| 3.577.589

sum 1 [1F 4 42 52 F/GI I54 2a I INVENTORS MARIO SERRANQ jf WILLIAM o. WOLF BY ATTORNEY-' W PATENIEU MAY 4 I87! 3; 577, 589

- sum 2 or 4 INVENTORS MARIO SERRANO WILLIAM D. WOLF AT TORNE Y-' PATENIED m 4 um SHEET3UF4 APPARATUS FOR TNCREASENG THE DENSITY OF THERMOPLASTIC FOAM This is a division of copending application Ser. No. 705,443 filed Feb. l4, 1968, now abandoned.

BACKGROUND This invention relates to a novel apparatus for densifying thermoplastic foam scrap.

Thermoplastic resins such as polystyrene, polyethylene,

, polyvinyl chloride, etc. having a foaming agent incorporated therein, may be extruded into a foamed sheet, and then formed into useful shapes by known thermoforming techniques such as vacuum, pressure, or drape forming or combinations thereof. As a by product of such forming processes, there is a great amount of scrap generated which cannot be recycled to form additional foam sheet until it has been further processed to increase its density, to a level approximating that of the original resin in the nonfoamed state. This is necessary because the high bulk of the low density foam material significantly decreases the capacity of a downstream foam extruder, which is based on its volumetric throughput rate. lf the rotational speed of the extruder screw 7 is increased to compensate for the lower density material, the

frictional work heat added to the material is increased and an extruder cooling problem arises.

Scrap of a similar nature is also generated by other foam forming processes such as in molding foamable beads by the well-known steam chamber technique or by equivalent methods. Scrap of the type to which the present invention applies may also be generated in processes where the finished foamed product is directly formed, e.g. by extrusion of foam directly into the useful article such as a log or blocklike product. Similarly the present invention is applicable to the reprocessing of off grade or damaged finished foam products. The invention may likewise be used to densify used foamed articles such as vending cups and the like, which present a waste disposal problem in their high bulk state.

Scrap as herein used is meant to include thermoplastic foam materials having a density substantially less than that of the nonfoamed resin, which it is desired to increase by reprocessing.

One method presently in use for conditioning foam scrap involves chopping the scrap into a relatively finely divided flake form and then stuffing the high bulk,'low density flakes into a standard vented extruder, whereupon through heat and substantial pressure generated within the extruder the scrap is melted and extruded in theform of a plurality of rods, which are then pelletized and later fed to foam forming equipment as a raw material resin. In so doing however, the time is increased during which the resin is exposed to elevated temperatures, which is commonly referred to as its heat history. For most resins it is desirable to keep the heat history as low as possible, since if it exceeds a certain level substantial decomposition may occur and the quality of the finished product may be af fected. Furthermore, thismethod is obviously expensive, and affects the economics of the overall foaming process due to the high cost of manpower and of the scrap processing equipment (i.e. the extruder built to withstand substantial pressure, cutter and auxiliary handling equipment). The extensive use of valuable processing floor space which is not involved in the actual production of the finished product is also disadvantageous.

SUMMARY OF THE ENVENTION It is therefore an object of the present invention to overcome the above elicited shortcomings of the various prior art methods of reprocessing foam scrap.

high heat, high shear, high-pressure recovery methods of the prior art.

It is a further object of the present invention to provide a novel apparatus and method whereby the density of thermoplastic foam scrap may be increased to a reprocessable level in a reduced time and at a minimum cost.

It is a still further object of the present invention to provide a novel foam scrap densifying apparatus which is of simple, low cost construction, is uncomplicated in its manner of operation and its need for adjustment and/or repair, and which lends itself to economical vertical orientation so as to conserve valuable plant floor space.

A still further object of the present invention is to provide novel densified curds which were formed by the novel apparatus and process of the present invention, and which are in a highly useful and convenient form for reprocessing as a feed material for foamed resin extrusion.

A further object of this invention is to provide a novel method of blending ingredients used in a foam forming process.

These and other objects and advantages of the present invention are accomplished by the provision of a device comprising a first member, which may be fixed or movable mounted, a second member for rotational movement therewith, and spaced from the first member so as to form a narrow chamber therebetween for receipt of foam scrap. One or both of the members may be provided with means for regulating the heat generated within the chamber, so as to control the temperature of the foam scrap being processed therein. Means are provided for feeding the scrap into the narrow chamber, whereupon the rotation of one member with respect to the other causes a mulling, rolling, agitating movement of the material being heated and worked therein at substantially atmospheric pressure, so as to crush the foam cells and produce rolled strands of resin which are increasingly densified as they progress towards the periphery of the members. The product emerges from the periphery in densified curdlike form after an unusually short residence time within the processing chamber. Other ingredients, such as colorants, blowing agents etc. may be blended into the densitied product by addition to the densifier along with the scrap feed. The scrap has preferably been reduced in size before feeding to the densifier, to minimize upstream space and handling problems.

Various other objects and features or advantages of the invention over those of the prior art will appear from a consideration of the following drawings and written description.

DESCRlPTlON OF THE DRAWlNG FlG. 1V is a partial plan view of the rotating member shown in FIG. ll wherein product guiding grooves have been formed therein;

FlG. V is a partially stylized, sectional view, similar to FIG. I of the drawings, but showing a modification to the apparatus, wherein the members have a generally conical shape;

FIGS. Vl, VII and VIII are schematic, elevational views showing alternate embodiments of various feed systems which may be used with the present invention; and

FIGS. IX, X, XI and X11 are schematic, elevational views of further alternate embodiments of the invention, depicting vertically oriented processing chambers.

DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring to the drawings, wherein identical numerals refer to identical parts, and more particularly to P16. l, there is shown a foam densifier 10 comprising an upper plate member 12 and a lower plate member 14. The upper member 12 is supported in static condition by means not shown, while the lower member 14 is mounted for relative rotation with plate 112. The

, two plates 12 and 14 are mounted in substantially superposed spaced relation to each other, and accordingly form a narrow,

generally horizontally oriented processing chamber 16 therebetween. 'Ihischarnber 16 is adapted to receive thermoplastic resin foam scrap to be processed by the apparatus.

The distance between the two members may be equal along their radial extents, or may vary somewhat dependent on the materials being processed and the desired shape of the densified product. Also, as shown, the distance between the members may be increased in central entry port area 24, so as to accommodate a greater amount of material at the feed section because of the high bulk, low density nature of the feed material. Alternatively, this increased area may be provided in rotary member 25 as shown in FIG. XII, at 27. Cutaway portion 27 of rotary member 25 in FIG. XII may even be equipped with radially extending vanes to aid in obtaining a bite on the low density material so as to more readily permit its passage into chamber 29. These vanes on the rotary member would create a slightvacuum depending on the rotary speed so as to pull the feed inwmdly, and then expel it radially outwardly into the processing chamber by means of centrifugal force. Plate 31 in FIG. XII, if desired, may also have a cutaway portion opposite portion 27 in the rotary member to further increase the size of the entry port area at this more or less stagnant center of the processing chamber.

' Returning to FIG. I, upper plate 12 is provided generally centrally thereof with an opening 18, which in turn is surrounded by a vertically orientated collar or flange member 2!) which may support a feed supply system. Collar 20 is further provided with means for forcing the low density foam feed scrap into chamber 16 under pressure, such as auger screw 22 which may be rotated by conventional exterior drive means not shown.

As mentioned, entrance portion 24 of chamber 16 in FIG. I is of large extent that the remaining portions of the chamber, with -this achieved by means of tapered wall portion 26 of upper member 12. Furthermore, the inner surface 27 of the lower member 14 which is the surface most proximate to upper member 12, may be provided with a domed boss 28 at its center, so as to radially outwardly direct the foam scrap as it is force fed into chamber I6.

Lower member M is mounted on shaft 30 which in turn is journaled by means of bearing 32 within a supporting frame 34. The lower end of shaft fill may be provided with a sheave 36 attached thereto, which is in turn connected to a conventional drive means not shown.

The drive shaft 30 of member M may be cored by means of channels 3% and 40, which respectively allow for the entrance and exit of a coolant. Channels 38 and as extend radially within the rotating member id either partially or entirely throughout its extent, so as to control its surface temperature. Generally the frictional heat generated by the'relative rotation of members I2 and M working upon the feed material generates temperatures sufiiciently high enough to elevate the temperature of the material to a level adequate to successfully operate the device. However,.occasionally it is desirable to provide for additional heating. Such heaters 62 are shown mounted on the outer surface of upper plate 12, though it should be recognized that such heaters may be located elsewhere. Further cooling means may be provided on the upper plate 12 as well, by means, for example, of the channeled collar 44 shown at the peripheral portions thereof.

Shaft 30 may further be .provided with adjusting means comprising an adjustable thrust plate as connected thereto, which in turn is provided with thrust bearing b and wear collar 52. Thus by vertical movement of adjusting screws 48 in either direction the distance between plates 12 and 14 can be varied to increase or decrease the volume of chamber I6.

sifted foam scrap as it emerges from chamber to. Cutting means 54 is preferably mounted at the periphery of the stationary plate. Beneath cutting means 54 is provided a generally circular collection hopper 56 for collecting the densified curds of material. Because of the relatively low temperature at which the process operates (to be described hereafter), the densitied curds may be readily collected without sticking together.

Turning now to FIG. ll of the drawings, plate 14 is therein shown as it would appear in operation, and particularly depicts formation of rolled strands 58 of partially densified foam scrap radially extending outwardly from central boss 28. Strands 58 are rolls of material being processed and are formed by the mulling or rolling action provided by the tow plates 12 and I4. Strands 58 progress or move radially outward to the periphery of plate 14, whereupon they are dislodged or cut into curds 60 which are typically shown in FIG. III of the drawings.

The degree'of melting or fusion in the present invention is a function of (a) the temperature of the surfaces of the plates, (b) the rotational speed of the rotating member(s), (c) the surface area of the plates, (d) the spacing of the plates from each other, (e) the surface finish of the plates, and (f) the feed rate of the material to the processing chamber. The energy imparted to the scrap being processed should not be so great as to raise the temperature to a point which results in melting the resin into a completely fused or molten-mass but rather should be maintained at a level short of complete fusion such that the resin is in a highly viscous state, capable of being worked and mulled by the plates so as to crush and substantially eliminate the voids and therefore its foam cell characteristics. This highly viscous operable state has been found to be about 75 F. on either side of the glass transition temperature region of the particular resin, wherein the material has some particulate or shape retaining form, and is preferably about 20 F. on either side of the glass transition temperature region of the resin being processed. Glass transition temperature region is herein defined as the temperature range in which there occurs a change in an amorphous polymer, or in an amorphous region of a partially crystalline polymer from a hard relatively brittle condition to a viscous rubbery condition.

At least one and preferably each of the inner surfaces of the plates are roughened to increase the mulling and frictional effect upon the material being worked into strands 58. In order to better facilitate the formation of strands 58, the inner surface of plate M may be provided with a plurality of grooves 62 approaching the shape of an involute. Such grooves 62 are shown in FIG. IV of the drawings, and serve to assist not only in the formation of strands 58 in that the material may roll around within the grooves, but may also aid in moving the strands effectively towards the periphery of plate 14, and even increase the wjoum time of the material in the processing chamber because of their curved nature. Other grooved configurations having a similar effect may also be utilized.

In FIG. V of the drawings, there is shown a modification of the apparatus of the present invention. Therein, with the exception of the conical shape of the upper stationary plate 112 and the lower rotating plate 114, like parts have been designated with the referenced numerals used in FIG. I. The operation of the modified form of the device shown in FIG. V is the same as that for FIG. I. This embodiment may be used when unusually long dwell times of the material in the processing chamber is desired because of the increased length of the path of polymer travel. Other plates shapes may also be utilized.

In FIGS. VI and VIII of the drawings there are shown plate densifrers similar to that of FIG. I, but utilizing alternate feed mechanisms for forcing the low density foam into the processing chamber. In FIG. VI feed screw 64 extends up into the throat of feed hopper 65, is integrally attached to hub 66 of rotating plate 68, and is therefore rotated by the same drive F [0. VIII depicts a reciprocating ram or pressure foot 70 in the up position, to permit the foam feed to fill in beneath it in the throat'of the hopper. It is then driven to the down position by means of a piston located in housing 72, operated by pneu- 6 required for the embodiments utilizing one fixed member.

In place of a rotary plate, aroller mountedeorttinuous belt positioned adjacent the stationary member may also be used.

The following examples e't forth in Table I were carried out matic, hydraulic or mechanical induced pressure. Fluid may with the apparatus shown in FIGII of the drawings, and will be introduced into and discharged from housing 72 through serve to explain the operation of the device. Foamed ports 74 and 76. Ram 70 forces feed material through the polystyrene sheet waspurchasedfromSekisui Inc, and from hopper throat into the processing chamber similar to the W. R. Grace Co. under its trade name Gryovac Foam. To manner of functioning of screw 64 inFIG. VI. Ram 78 in FIG. simulate scrap, the foam sheet in each instance was cut into IX operates similarly. Screw feeding is preferred, however, fine flakes by means of a laboratory fly knife cutter and then because it functions to continuously introducematerial to the screened using /32-inCheS. hole ize screen. The density of processing chamber. Hopper 77 in FIG, VIII may be qui ed the general purpose nonfoamed. resinous polystyrene from with a feed pipe 80 and cover 82. which the foamed sheet was formed for both Sekisui and W.

FIG. XI depicts an alternate feed screw 84 rotated by R. Grace samples is in'the range of between about 1.05 to 1.08 separate external drive means, not shown, which is horizong. per cc., whereas the density of the finely divided foam scrap tally mounted at a right angle to the axis of the feed hopper, as generated from the foamed sheet was respectively 0.101 and opposedtothevertical mounting ofFIG S. I V and 0.105g. per cc. for the Sekisui and W.. R. Grace samples.

FICE. VII, IX and X show densifying apparatus utilizing off Tire roar; speed and surti'efeifiiieraure of the Havana center feed systems. FIG. VII depicts a horizontally oriented plate is set forth for each example in Table I. The temperature apparatus, and FIGS. IX and X depict vertically oriented apof the stationary plate at the beginning of each run was at an paratus with each having feed points which are radially offset ambient temperature of about 70 F. and rose during operawith respect to the axial centerline of the plates. Use of an off tion to a temperature approximating that of the rotating plate. cent er'feed to the processing chamber for the horizontally The temperatures of the rotary plate were obtained by means oriented parallel plate densifier of FIG. VII. may simplify and "of a direct contact pyrometer. The pressure within the improve introduction of material between the plates, since processing chamber between the plates was atmospheric in all surface portion 84 of rotary member 86 (FIG. VII) is moving cases.

' TABLE I Feed Rotary plate Plate Resultant curd stock cleardensity Speed Temp. anee Diameter Length Density Run number .100.) (r.p.m.) (F.) (in.) (in.) (in.) (gmsJec.

o. 093 150 ca. 200 4 %-1 0. 935 o. 093 150 225 m saws 54-2 0. 971 0. 093 150 170 an; t g- 4 0. 95s 0. 093 150 220 Me l'ta-l s 994 1. 125 150 225 V8 54-54 %1} 0. 780 I. 125 225 lz $62-$16 54''% 012 across the opening in feed port 88 of stationary member 90. In so doin g t.he feed material is continuously swept away from the feed port and into the processing chamber 92. Plate 90 may be cut away as at 94 on the downstream side of the feed port to permit feed entry of the scrap particles between the plates. Though a forced feed system may beused with this type of structure, it may be possible to utilize gravity feed as shown in FIG. VII, because of the cleaning action of the off center feed port by the rotating plate.

FIG. VII also illustrates a clearing paddle 96 attaehe dTo rotary plate 86 by means of arm 98 which may be used to maintain a constant level in trough 100 and move any buildup along in front of it to a central collection point not shown.

FIGS. IX- XlI depict the vertical adaption of a plasfic foam densifier with offset feeding, but it should be understood that central feeding may also be used in these embodiments. Vertical orientation may provide easier access for maintenance and adjustability of parts. The effect of gravity should not affect operation because of the gripping action on the foam by the plate members. Discharge is still anywhere around the periphery of the plates. Also, as shown in FIG. X, the stationary member 102 may be only a partial plate to the extent that its processing surface area is equivalent to only a portion, e.g. about one-half of that of the. rotary plate, with an off center feed chute 104 feeding material between the plates slightly above the horizontal centerline of the assembly. Plate 102 may have chamfered edges I06 and 108 to aid in introducing and discharging the material. g

A It should basements tirefeatures-sown in the various embodiments described above are interchangeable. Obviously orientation of the processing chamber along a plane intermediate the horizontal and vertical orientations previously described is also feasible Though a fixed member and a rotary member have been shown throughout the various embodiments, it is obvious that each member could be adapted to rotate at a different speed and in the opposite direction from the other, though this requires use of more complicated drive equipment over that The resultant densities ofthe curd material in each case showed that the apparatus of the present invention increased the density to a level which very closely approached that of the nonfoamed virgin material. It should be noted that the temperatures utilized herein are particularly appropriate for polystyrene foam scrap and that accordingly temperatures of varying scope would be utilized for different resinous materials such as polyethylene, polyvinyl chloride etc. As previously noted, it is particularly important that frictional heat, as well as any heat supplied by outside sources should be regulated so as to render the foam scrap material being processed short of the completely fused liquid state, since it is necessary that the material remain in a highly viscous state so'that it can be significantly worked and mulled by the relative rotation of the plates. In some cases it may only be necessary to heat the plates at start up with the frictional heat generated during operation being thereafter adequate or even excessive so that cooling may be required. In general, the temperature of the plate surfaces during operation should be maintained between about l00350 F. and preferably between about l6024 0 F. The operating pressure in the processing chamber should be substantially atmospheric i.e. with no substantial back pressure in excess of about 25 p.s.i., so as not to contribute to the shear effect which promotes depolymerization and breakdown of the polymer being processed.

Though the foam scrap may be directly fed to the densifying apparatus in the same condition in which it is generated, it is preferable that the material be cut and reduced in size upstream of the densifier in order to reduce its bulk and facilitate handling.

Rotor speeds of between about 10 to 500 rpm, and plate clearances of between about one-sixteenth to five sixteenths inch and preferably between about one-sixteenth to three-sixteenths inches have been found to be particularly suitable in the present invention. The plate clearance utilized, however, is directly related to the sciap foam feed particle size.

As an important feature of the present invention'additional ingredients may be blended into the scrap as it is being passed essentially atmospheric pressure.

through the densifying apparatus, in order to eliminate a separate blending step and the apparatus required therefor, which would otherwise be necessary in the process between the densifier discharge and the feed to the downstream-foam forming equipment. Also, materials such as solid blowing agents which decompose at elevated extrusion temperatures (for example 250-'400 F.) could be effectively added to the scrap. in the densifying operation, which is carried out for a shorter period and at a lower temperature (for example 165- 240 F.) wherein such decompositionis insignificg ip L i quid blowing agents might be. added to the cut feed scrap just prior to .its entry into the densifie'r. Virgin nonfoamed polymer could also be added so that the discharge from the densifier could comprise the entire direct feed to the downstream foam The densified foam product resulting from the process of the present invention has a very low heat history of generally less than about minutes exposure during reprocessing to temperatures greater than an ambient temperature of about 70 R, which is lower than that obtained by processing through a conventional die mounted on the discharge of an extruder. Otherwise the products in each case may be similar. in appearance. Low heat history is important particularly with heat sensitive materials such as, for example, polymers of vinyl the recovered reprocessed product generally approaches to,

within about 60 to I00 percent of the density of the nonfoamed virgin material because of the substantial collapse of the foam cells during the mulling, shearing type of working in the relatively low temperature processing zone operating at The present invention f'i ds wide utility in the scrap reclaim field, and may broadly be utilized to'transform thermoplastic film scrap of all types as well as thermoplastic foam scrap into a useful form to facilitate further processing. The apparatus is simple, the processing conditions are mild, and the product relatively thin materials which iri .t u rn also facilitates temperature control from the standpoint of heattransfer rate and simplicity in construction of the heating and/or cooling means.

- In describing the invention reference was made to preferred embodiments. Those familiarwith the art will recognize that additions, deletions,substitutionsor ot h er modifications may be made witliin thepurview of the invention as defined in the appended claims v We claim:

1. Apparatus for increasing the density of thermoplastic foam scrap which comprises:

a. a first stationary plate having a generally centrally located feed opening therein for receipt of said thermoplastic foam scrap;

b. a second, rotat'ably mounted plate spaced from said first plate, said plates having generally coextensive peripheral dimensions and being positioned in generally superposed relationship to each other the space between said plates forming a narrow processing chamber having a discharge area open to the atmosphere at and extending around the periphery of said plates for emitting scrap from the apparatus after passing through said processing chamber;

c. the inner surfaces of at least one of said plates being roughened to promote mulling contact with said foam scrap material;

d. means for forcing the foam scrap through the opening in said first plate into contact with the inner rotatable surface of said second plate;

e. means associated with at least one of said plates for imparting heat to the scrap within said chamber; and

f. cutting means situated proximate the edges of the plates for cutting the densified foam scrap asit emerges from the discharge area of the processing chamber.

2. The apparatus of claim 1 wherein said cutting means comprises a plurality of knife members spaced from each other and mounted on the stationary plate such that they protrude toward the rotatably mounted plate.

3. The apparatus of claim 1 including cooling means associated with the first stationary plate for regulating the teming the densified scrap includes a leveling member projecting radially outward of the periphery of the second plate, for

directing densified scrap built up around the periphery of the processing chamber toward a central collection point. 

2. The apparatus of claim 1 wherein said cutting means comprises a plurality of knife members spaced from each other and mounted on the stationary plate such that they protrude toward the rotatably mounted plate.
 3. The apparatus of claim 1 including cooling means associated with the first stationary plate for regulating the temperature of the scrap in the processing chamber.
 4. The apparatus of claim 1 wherein the means for collecting the densified scrap includes a leveling member projecting radially outward of the periphery of the second plate, for directing densified scrap built up around the periphery of the processing chamber toward a central collection point. 